Winding Machine Motor Control Balancer Modes
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Solution Overview
Problem
Existing winding machines lack a method to effectively control the torque of drive motors at balancer upper and lower limit positions, preventing balanced operation and assistive lifting/lowering without interrupting torque control.
Innovation Solution
A winding machine with a motor control system that includes balancer modes for assistive torque and non-assistive torque control, using a servo motor and load detection to adjust torque commands based on load torque and operating force, allowing for balanced operation and position regulation without interrupting torque control at specific limit positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If torque control is performed in balancer mode with assist torque, then operational efficiency is improved, but control complexity increases due to multiple balancer modes and position ranges
Solution Approach 1:
The control system dynamically switches between first and second balancer modes based on the operational position (first position range vs. second position range) and the direction of operating force. This dynamic adaptation allows the system to optimize torque control for different operational scenarios, improving overall efficiency while managing complexity through context-aware mode selection.
Solution Approach 2:
The system changes the torque command value parameters based on position and operating force direction. In the first position range, assist torque is added to the torque command value, while in the second position range, the operating force direction determines whether assist torque is applied. This parameter adaptation enables efficient torque control across different operational conditions.
2Object-affected harmful factors
If the cargo is lifted to fit within the first length L1, then collision with floor is prevented, but the lower limit position of the cargo cannot be specifically controlled
Solution Approach 1:
The control unit continuously monitors the position of the cargo and the direction of the operating force, using this feedback to determine whether to apply assist torque. This feedback mechanism enables precise control of the cargo's lower limit position while ensuring it remains within the safe first length L1, preventing both collision and excessive lifting.
Solution Approach 2:
The system dynamically adjusts the torque control based on the cargo's position and operating force direction. By switching between different balancer modes depending on whether the cargo is in the first or second position range, the system achieves both collision prevention and precise position control.
3Ease of operation
If torque control is interrupted at balancer upper/lower limit positions, then position regulation is simplified, but balanced operation and assistive lifting/lowering cannot be maintained
Solution Approach 1:
The control system dynamically maintains torque control continuity by switching between first and second balancer modes at position limits. Rather than interrupting torque control, the system adapts the control parameters based on whether the cargo is at the upper or lower limit position and the direction of operating force, ensuring both balanced operation and assistive functionality are maintained.
Solution Approach 2:
The torque control action continues without interruption throughout the operational range. The system maintains continuous torque control by transitioning smoothly between different control modes (first balancer mode with assist torque, second balancer mode without assist torque) based on position and operating force direction, ensuring uninterrupted balanced operation.
Data Source
AI summary
A winding machine wherein a motor control means is able to control driving of a drive motor in a balancer mode, and the balancer mode includes a first balancer mode in which driving of the drive motor is controlled based on a first torque command value with an assist torque that assists the operating force added thereto, and a second balancer mode in which driving of the drive motor is controlled based on a second torque command value that does not assist the operating force, and a lifting/lowering position range is set to a first position range where control is performed in the first balancer mode regardless of the direction of the operating force being in either the winding up or winding down direction, and a second position range where control is performed to select whether control is performed in the first balancer mode or in the second balancer mode.